4 ways to make products from recycled plastic.
The use of recycled plastic material in plastic injection moulding. 4 recipes for different applications and finishes.
Many customers ask us if we can use bio-based plastics or recycled plastic materials in our productions. Obviously, the answer is YES!
However, there are several ways to make recycled plastic products.
Recycled plastics, recyclable plastics, bio-based plastics, or biodegradable plastics – Let's get the facts straight!
There is a very large variability in the recycling rate of plastics by country, but especially by family of plastics. Indeed, 7 families of recycling exist for plastics:
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- PET
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- HDPE
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- PVC
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- LDPE
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- PP
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- EPS
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- OTHER
You will therefore have already understood that «exotic» bio-based plastics are already classified in «OTHER», Biobased plastics are not automatically recyclable ! and the plastics Biobased products are not automatically biodegradable!
On the other hand, plastics recycled are necessarily recyclable (QED), but the reverse isn't really true (at least, not in practice!)
The subjects such as ABS, The PC (Polycarbonate), PU (Polyurethanes), PA (Polyamides), are also returned to the «OTHER» segment».
This doesn't mean they aren't recyclable plastics… the proof is that we make products from these materials, from recycled plastics. (so it's technically possible, and supply chains exist!!)
Two approaches for incorporating bio-based or recycled materials:
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- It's make or break (literally and figuratively)
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- We'll sit down, analyse, and do things in order.
Which one do you think was chosen?
Let's take a simple example (a piece of our logo, this will prevent others from nicking our images...)
thermoplastic"thermoplastics recycled" />Injection moulding of recycled 100%
70% recycled injection moulding (virgin/recycled blend)
Injection sandwich
2K injection moulding
Our press 550 tonnes material sorting, allows for the combination of both sandwich injection and two-component (or bi-injection) moulding
To facilitate end-of-life recycling, we recommend using materials from identical families, which will make sorting easier. However, it is possible to combine different material families. (follow our guide)
Note to designers and product managers The use of recycled plastics can influence the choice of colours for the finished product, or its appearance (texture, finish, etc.).
We have two choices in this situation:
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- Claiming the use of recycled plastics (assuming the appearance, communicating it, and making it a marketing argument)
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- We hide it (so we use technological devices to hide it)
It may be interesting, for example, to use mechanical reinforcements (fibreglass, mineral filler, etc.) in the «hidden» part of the product, in order to give it a little more mechanical resistance, without having the drawbacks on the visible surfaces.
Hybster's project managers are at your disposal to assist you.
Interesting links on recycled plastics:
❓ Frequently Asked Questions
What is the difference between recycled plastic, recyclable plastic, bio-based plastic and biodegradable plastic?
Recycled plastic comes from material that has already been processed and reprocessed, therefore it is necessarily recyclable. Bio-based plastic is made from renewable plant resources, but is not automatically recyclable. Biodegradable plastic breaks down in the natural environment. These three properties are independent of each other.
Voici 4 méthodes pour fabriquer un produit en plastique recyclé par injection : 1. **Injection mono-matière avec plastique recyclé :** Il s'agit de la méthode la plus simple, où l'on utilise uniquement du plastique recyclé (souvent pré-traitement comme broyage et granulation) pour fabriquer une pièce en une seule étape. 2. **Injection multi-matières avec une partie plastique recyclé :** Dans cette approche, on utilise le plastique recyclé pour une partie de la pièce et un plastique vierge ou un autre type de plastique recyclé pour le reste. Cela permet de bénéficier des propriétés du recyclé tout en assurant des caractéristiques spécifiques à d'autres sections. 3. **Moulage par injection-soufflage avec plastique recyclé :** Cette technique, qui combine injection et soufflage, peut être utilisée pour fabriquer des pièces creuses comme des bouteilles ou des contenants en utilisant du plastique recyclé. 4. **Moulage par injection-compression avec plastique recyclé :** L'injection-compression est une variante qui offre une meilleure tolérance dimensionnelle et un état de surface supérieur. Elle peut être appliquée avec des plastiques recyclés pour des pièces de haute précision.
The four methods are: 100% recycled injection moulding where appearance is not critical; a virgin/recycled blend containing up to 70% recycled material; sandwich injection moulding with an outer skin made from virgin material and a recycled core; and dual-material injection moulding with the aesthetic part made from virgin material and the technical part from recycled material.
Can a product be manufactured using 100% recycled plastic via injection moulding?
Yes, it's technically possible when the specifications allow for it and the visual aspect isn't paramount. This method is suitable for technical or hidden parts. The colour, texture and finish can vary from one batch to another depending on the origin of the recycled material supplied.
What is sandwich injection with recycled plastic?
Sandwich injection is a process that injects two materials simultaneously into the same mould: an outer skin of virgin material for appearance and colour, and an inner core of recycled material. The part appears new on the outside while containing a significant amount of recycled plastic.
What is two-shot injection moulding with recycled plastic?
Bi-material injection, or overmoulding, combines two distinct materials in a single part, with each remaining visible. The aesthetic section is moulded from virgin material for appearance, while the functional technical section uses recycled plastic. Hybster masters this process on its 550-tonne tri-material press.
What is the maximum percentage of recycled plastic that can be incorporated by injection moulding?
It is technically possible to incorporate up to 100% recycled plastic where the specifications permit. When blended with virgin material, a recycled content of up to 70% is typically achievable. The optimal ratio depends on the intended application, the mechanical requirements and the desired appearance.
Les 7 familles de recyclage des plastiques sont : 1. PET (polyéthylène téréphtalate) 2. HDPE (polyéthylène haute densité) 3. PVC (polychlorure de vinyle) 4. LDPE (polyéthylène basse densité) 5. PP (polypropylène) 6. PS (polystyrène) 7. Autres (couvrant tous les autres types de plastiques, y compris les mélanges)
The seven recycling families are identified by codes 1 to 7: PET, HDPE, PVC, LDPE, PP (polypropylene), EPS (expanded polystyrene) and the «OTHER» category, which groups all other engineering plastics such as ABS, polycarbonate, PU or polyamides.
Are ABS, polycarbonate and polyamide recyclable?
Yes, these engineering plastics are recyclable even though they are classified under the «OTHER» category in standard recycling codes. Supply chains are in place, and Hybster regularly manufactures products made from these materials in recycled versions: ABS, PC, PU and PA6 polyamides.
Are bio-based plastics automatically recyclable?
No, a bio-based plastic is not systematically recyclable. Many exotic bio-based materials are classified under the «OTHER» category of standard recycling codes, which complicates their processing in recycling streams. The bio-based nature concerns the origin of the material, not its recyclability.
Are bio-based plastics automatically biodegradable?
No, bio-based and biodegradable are not synonymous. A bio-based plastic is made from renewable resources but can be entirely non-biodegradable, such as bio-PET. Conversely, some petroleum-based plastics can be biodegradable. These two properties are perfectly independent of each other.
How does the use of recycled plastic influence the appearance of the finished product?
Recycled plastic can alter the colour, texture, and surface finish of the final product. Two strategies are possible: claiming the different appearance as an eco-marketing argument, or masking it through processes such as sandwich injection or the use of mineral fillers in the hidden part.
How to facilitate the end-of-life recycling of a plastic product?
Prioritising materials from the same recycling family for the entire room greatly simplifies end-of-life sorting. If multiple families are necessary, choose technically separable combinations. Monomaterial design remains the most favourable solution for the circular economy of plastics.
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